Marshe

In our previous article, we said: the assembled test mold is ready for its first real challenge – the mold trial. 

This article walks you through how we test, inspect, and ship your first batch of samples. 

So when the package arrives at your door, you know exactly what to expect.

Trial Mold Sample – First Custom LED Lens Samples

We mount the mold on our injection molding machine. Then we load the same optical-grade material used for production lenses – PC, PMMA, or whatever your project needs.

During this custom lens mold trial, we use only a single cavity and produce just 1 to 10 sample lenses.

Then we quickly test the light spot and all key data.

At this stage, we focus on:

Fill quality – Does the material reach every corner of the cavity? Any short shots or flow marks?

Surface finish – Does the lens surface match the mold polish – smooth, textured, or glossy?

Ejection – Does the lens release cleanly, without sticking or deformation?

Dimensional stability – Are critical dimensions within tolerance from the very first shot?

A mold trial is not a one-time event. We usually run multiple cycles to let the mold reach a stable temperature and pressure rhythm.

The first few shots are just warm-up. Real evaluation starts after the mold runs steadily.

Quality Inspection for Custom LED Lenses

Once the mold runs smoothly, samples go to quality inspection. This is not a quick glance. It's a systematic check of everything that affects lens performance and fit.

Optical Performance Check

This is the key part. We compare the beam pattern, beam angle, and brightness against your approved optical design. The IES file from the design phase is our reference. The actual light output must match.

We use an integrating sphere to test total luminous flux, and a goniophotometer to test beam angle and light distribution. Results go into a test report. You can compare it directly with the original design specs.

Dimensional Check

Every critical dimension is measured – outer diameter, height, thickness, mounting features. We use precision calipers, micrometers, and for complex shapes, sometimes a CMM (coordinate measuring machine).

Why such precision? Because a lens that is 0.2mm off may not fit into your luminaire. Or worse – it fits, but the focal point shifts, and your beam distribution changes.

Visual Inspection

Our inspectors check every sample under good lighting. They look for:

Surface defects – scratches, sink marks, flow marks

Contamination – dust, black spots, or material degradation

Clarity – any haze or cloudiness in the optical zone

Edge quality – clean, sharp edges without flash or burrs

Each lens is inspected individually. No spot checks at this stage. When we are validating a new mold, every sample is examined carefully.

Cleaning

Many factories skip this detail, but it matters. After inspection, every LED lens is cleaned. We remove any dust, fingerprints, or residual mold release. The lens that arrives at your door is ready to install.

Sample Shipment – Packed Well, Shipped Fast

Your samples pass inspection. Now they need to reach you – safely and quickly.

Packaging

We don't just throw lenses into a box. Each lens goes into its own inner pack first – depending on lens size and surface sensitivity – to prevent scratches during transit.

Then the inner packs are placed into a sturdy carton with dividers to ensure lens surfaces are not damaged.

If the shipment is especially sensitive or going a long distance, we add extra cushioning.

We make sure you receive exactly what we tested – clean, clear, and ready for your own evaluation.

Shipping

We ship according to what best fits your timeline and budget:

Courier (DHL, FedEx, UPS) – Fastest option. Usually 3–7 business days depending on destination. Best for urgent sample evaluation.

Air freight – Good balance of speed and cost for medium quantities.

Sea freight – Most economical for large production volumes, but longer transit time.

At SunshineOpto, we have 16 years of export experience. We understand customs documents. We know how to pack for international shipping. And we know which shipping method works best for each destination.

Tell us your preference, or let us recommend the best option for you.

What to Do When You Receive the Samples

We recommend you check the following:

Assembly test – Fit the lens into your actual luminaire. Does it snap in, screw in, or seat correctly?

Optical test – Turn on your LED and look at the beam. Does the beam pattern match what you expected from the IES file?

Visual check under your own light – Inspect clarity, surface finish, and overall appearance under your lighting conditions.

Take notes – Anything you want to adjust – even small tweaks – write it down and send us photos if possible.

If you need adjustments, we modify the mold and try again. This back-and-forth continues until you sign off on the samples. Only then do we move to mass production.

Why Choose SunshineOpto for Mold Trial & Sample Delivery?

Real testing, not just simulation – We test real molded parts with calibrated optical equipment. What you see in the report is what you'll see in your luminaire.

Systematic inspection – Optical, dimensional, visual, and cleanliness checks. Four layers of verification before anything leaves our factory.

Careful packaging – Individual inner packs plus sturdy outer cartons. Your samples arrive in the same condition they left our inspection table.

Fast and flexible shipping – DHL, air, or sea. 16 years of export experience means your samples arrive quickly and safely.

We don't stop until you're satisfied – The mold trial and sample stage is iterative. We adjust, re-test, and re-ship until you give the green light.

Frequently Asked Questions

Q: How many samples do you send for approval?
A: Usually less than ten, but we can adjust based on your needs. That's enough for you to test thoroughly on multiple luminaires.

Q: How long does it take from mold trial to sample shipment?
A: After the mold trial is complete and samples pass internal inspection, we ship via courier. Transit time depends on your location.

Q: What if I find a problem with the samples?
A: Tell us exactly what you see – with photos if possible. We'll adjust the mold or process and send a new set of samples. This iteration is part of the process. Reasonable adjustments are included at no extra charge.

Ready to see your first real parts?

Your mold is ready for its first trial. The next step is to see real lenses come out – and then hold them in your hands.

From mold trial to inspection, cleaning, and packaging – we know every step well.

We check every detail. We pack carefully. And we ship to your door. Then you test. You tell us yes or no. We keep improving until everything is perfect.

Click the chat button on our website or email us directly!

Let's get the first real samples into your hands – you're just one step away from full production.